Glare shields s@ck

Freemasm · #1 02-27-2021, 12:37 PM

Wasting a lot of aluminum here. The glare shield is a bit “special” as the forward part has to be formed to follow the contour of the airframe while the back most edges are nearly straight to clear the WS bow. Would love to cut down on my scrap and be more efficient. Any wisdom, methods, tricks, whatever anyone could share would be appreciated. Here or PMs, whatever worked for you. Much thanks.

Freemasm · #2 03-04-2021, 09:49 AM

I've calmed down some now. I've done plenty of shrinking/stretching in the past. I was trying to tweak the glare shield for clearance at the windshield bow. The stretcher tore the 032; unfortunately of an almost finished, compound curved part. It's an ATS tool and never witnessed this before, A product of work hardening the sheet during hand forming? Anybody else? Theories?

F1 Rocket · #3 03-04-2021, 03:23 PM

I don’t remember mine being that hard to fabricate. I started by rolling the rough cut panel, gently in the center and more aggressively towards the sides. The sides were the tricky part and did require a bit of shrinking. I just went easy at it until it fit.

Danny

Freemasm · #4 03-05-2021, 08:22 AM

As you know, laterally the required curve between the forward and rear of the glare shield is significantly different. The only somewhat tricky part is trying to keep some clearance between the WS bow and top of glare shield where they cross. My target was 1/8" hence my missteps with the stretcher. Will probably settle for a clearance greater than zero. The GS pieces aren't yet riveted or even spliced in the middle. If you even look at it, the aforementioned clearance is lost. Starting to think that a small non-metallic shim/bumper/etc. between the two at each side would make some sense to stiffen it at least temporarily. My first build and I'm trying to avoid any future related rework. Been there/done that many times already. If I ever complete this build, I'll actually be prepared to build an aircraft. Living and learning. Yes, the GS opening is only rough cut right now.

vlittle · #5 03-05-2021, 08:58 AM

Here's my pics. You can see where I shrunk the metal.

Everything (slider canopy) http://www.vx-aviation.com/sprocket/canopy.htm

Freemasm · #6 03-07-2021, 12:32 PM

Anybody want to share some pix of their final GS shapes? Any rationales, gothca’s, things they would have changed etc? Would be greatly appreciated.
Much Thx.

Robertcropdust · #7 03-07-2021, 05:31 PM

Here’s a few pics.

Freemasm · #8 03-08-2021, 06:05 AM

@Robertcropdust. Did you have the forward windscreen before deciding on that GS shape? Wondering if there's extra material on the plexi to account for the various shapes.

F1 Rocket · #9 03-08-2021, 06:13 PM

I had my boot cowl and glare shield completed before the speed slope windshield was available. The speed slope had plenty of extra material to trim.

Freemasm · #10 03-15-2021, 07:22 AM

Forming is finished, finally. Assuming it’s better to delay the riveting for now to ease access. Something to think about for future builders at this junction, taping an 0.125 (thickness = builder preference) to the top of the windshield bow gusset is probably a good idea to help maintain related clearance when match drilling glare shield to doubler. The resulting compound curve of the GS makes for a relatively stiff part; very little play for final fit. Took way more tries than it should have.